Preparation of vanadium(IV)bis(metaphosphate) hydrocarbon oxidation catalyst containing an actinide or lanthanide series metal

ABSTRACT

A method for the preparation of a cerium or thorium (lanthanide or actinide metal) promoted single phase vanadium(IV)bis(metaphosphate) catalyst useful for the vapor phase oxidation of hydrocarbons and particularly the oxidation of linear C 4  unsaturated olefins to prepare maleic anhydride.

BACKGROUND OF THE INVENTION

This invention is directed to a novel method for the preparation of a cerium or thorium (a lanthanide and actinide series metal) promoted single phase crystalline vanadium(IV)bis(metaphosphate) catalyst which provides good yields of and selectivities to maleic anhydride by the oxidation of unsaturated aliphatic hydrocarbons.

Prior art processes are known for the preparation of phosphorus-vanadium-oxygen catalyst systems which include other metals or metal compounds as potential yield improving co-catalysts such as molybdenum, copper, and uranium oxides or other oxides incorporated into the catalyst system during preparation. These catalysts systems however, as well as other catalysts showing some activity for the production of maleic anhydride have generally proven to be unsatisfactory for commercial application and leave a lot to be desired since the yield and selectivity to maleic anhydride is usually low.

Phosphorus-vanadium-oxygen catalysts are usually prepared by reducing vanadium pentoxide to vanadium(IV) in water or an organic solvent with a suitable reducing acid or agent. A source of phosphorus, usually phosphoric acid, is mixed with the vanadium solution to produce a catalyst precursor which is heated to give the production catalyst. Co-catalysts are usually incorporated into the catalyst system during the solution stage of preparation and by such process there is a risk of also reducing the co-catalyst or added metal compound. The present invention avoids this problem.

U.S. Pat. No. 3,907,835 discloses the preparation of a catalyst comprising an admixture of vanadium, uranium, phosphorus and oxygen for the gas phase preparation of maleic anhydride.

U.S. Pat. No. 3,904,652 describes a solution or "reflux" method for the preparation of a phosphorus-vanadium-oxygen complex catalyst containing one or more activators selected from zinc, copper, bismuth or lithium intimately combined therewith.

U.S. Pat. No. 3,366,648 describes a solution method employing reducing agents to form a vanadium-phosphorus catalyst complex along with a phosphorus stabilizer of an alkali metal (Group 1a metal) compound useful for the preparation of maleic anhydride.

There is no known prior art which describes the preparation of a lanthanide or actinide series metal, i.e., cerium or thorium, promoted crystalline VO(PO₃)₂ hydrocarbon oxidation catalyst employing a liquid phase reaction of vanadyl sulfate, along with ceric oxide, cerous nitrate or thorium dioxide, and acetic anhydride and phosphorus pentoxide followed by a thermal treatment with the liberation of gases to form a catalyst precursor.

SUMMARY OF THE INVENTION

This invention relates to a novel method for the preparation of a single phase crystalline vanadium(IV)bis(metaphosphate) catalyst containing a lanthanide (cerium) or actinide (thorium) series metal with improved catalytic activity for an air or oxygen partial oxidation of an unsaturated aliphatic hydrocarbon such as 1-butene, 2-butene and 1,3-butadiene or mixtures thereof at temperatures of from about 300° C. to 600° C. by contacting the hydrocarbon and air or oxygen with the cerium or thorium promoted vanadium(IV)bis(metaphosphate) catalyst at contact times of from about 0.2 to 5 seconds of reactant feed over the catalyst, prepared by the instant method.

It is a primary object of this invention to provide a novel method for the preparation of a cerium or thorium (lanthanide or actinide series metal) promoted single phase crystalline vanadium(IV)bis(metaphosphate) catalyst useful as an oxidation catalyst for the preparation of maleic anhydride.

It is another object of this invention to provide a novel method of adding cerium or thorium, in the form of cerous nitrate, ceric oxide or thorium dioxide, to a vanadium-phosphorus-oxygen catalyst system and thus ultimately forming, apparently by some chemical interaction and not by mere physical admixture, a cerium or thorium promoted VO(PO₃)₂ oxidation catalyst.

These and other objects and advantages of this invention will become apparent from the description of the invention which follows and from the claims.

DESCRIPTION OF THE INVENTION

In accordance with the present invention, cerium or thorium promoted single phase crystalline vanadium(IV)bis(metaphosphate) VO(PO₃)₂ compound is prepared by a novel method which provides a cerium or thorium containing catalyst useful as a hydrocarbon oxidation catalyst.

The instant method for the preparation of the novel improved cerium or thorium promoted single phase crystalline oxidation catalyst involves a liquid phase interaction between vanadyl sulfate (VOSO₄), cerous nitrate, ceric oxide or thorium dioxide, acetic anhydride and phosphorus pentoxide forming a slurry with the liberation of exothermic heat. Excess liquid is generally decanted from the resulting slurry which is then subjected to a thermal treatment for a period sufficient for the liberation of gases and the forming of a cerium or thorium-phosphorus-vanadium reaction product. The undecanted slurry may per se be subjected to thermal treatment with the acetic anhydride being vaporized off along with the gases. Stoichiometric amounts of the vanadyl sulfate and phosphorus pentoxide are generally employed in preparing the cerium or thorium promoted VO(PO₃)₂ compound but excess amounts may also be employed and the excess residue removed, by water washing, after reaction, to form the catalyst precursor. The molar ratio of the cerium or the thorium to vanadium, employed in the process in the form of vanadyl sulfate and cerous nitrate, ceric oxide or thorium dioxide will generally be in the range of from about 1:10 to 1:150 preferably 1:90 although larger or smaller amounts may be employed. The amount of acetic anhydride employed in the process can range from about 1 to 4 moles preferably 2 to 3 moles per mole of the combined vanadyl sulfate, phosphorus pentoxide and cerium or thorium compound present. Greater amounts of acetic anhydride may be used but generally are not required to provide the desired promoted VO(PO₃)₂ catalyst.

The liquid phase reaction is generally carried out at ambient temperatures e.g., 20° C. to 26° C. although higher or lower temperatures may be used. The thermal treatment of the slurry mixture will proceed at temperatures of at least 325° C. and temperatures as high as 475° C. or higher may be used to liberate the reaction gases. It is generally preferred to carry out the thermal treatment at a temperature of between about 400° C. and 460° C. to obtain a convenient rate of reaction.

After preparation and water washing, the cerium or thorium promoted VO(PO₃)₂ compound is generally dried at 120° C. calcined in air at temperatures between about 450° C. and 500° C. or higher for at least two hours, then broken up and sieved to the appropriate Tyler Standard Sieve mesh size, usually for fixed bed reactor use. The resulting cerium or thorium promoted VO(PO₃)₂ compound (catalyst precursor) which generally has a surface area of approximately 4-7 m² /g., requires a period of activation or conditioning for use in oxidizing the above indicated hydrocarbons. For the activation or conditioning the cerium or thorium-vanadium-phosphorus-oxygen catalyst precursor is subjected to temperatures which are at or above the hydrocarbon oxidation reaction temperatures which are from about 300° C. to 600° C. preferably from 50° C. to 550° C., under a flow of from about 0.2 volume percent to about 2.0 volume percent, preferably 0.5 to 1.5 volume percent in air of said hydrocarbon or mixture of hydrocarbons, to be oxidized and at an apparent contact time of from about 0.5 to 3.0 seconds, preferably 0.75 to 1.5 seconds for an appropriate period, to enable the hydrocarbon conversion to reach 90 percent or more, with subsequent temperature and flow rate adjustments to desired oxidation reaction conditions. Water vapor (steam) e.g., from about 10 to 35 mole percent may be added to the reactant hydrocarbon gases during the activation period and subsequent oxidation reaction. The length of time required for activation or conditioning of the catalyst precursor and to permit the catalyst performance to become stabilized depends on the temperature employed and contact time of the hydrocarbon-air mixture but generally will be from about 4 to 8 hours. Apparent contact time calculated in seconds is equal to the flow rate of the hydrocarbon-air feed mixture at cc/second, per cc of catalyst measured at ambient conditions. Once activated the cerium or thorium promoted VO(PO₃)₂ exhibits excellent performance as a catalyst for the oxidation of e.g., 1-butene, 2-butene, and 1,3-butadiene, or mixtures thereof, to maleic anhydride for extended periods of time.

The cerium or thorium promoted VO(PO₃)₂ catalyst of this invention may also be prepared in the presence of a suitable carrier such as silica gel, aluminosilicates, alumina, silicon carbide and carbon to provide a support for the catalyst and thus a surface which gives physical strength and stability to the catalyst material as well as an increased surface area. The support is generally added in an amount of at least 10 percent by weight and preferably between about 50 to 60 percent by weight of the combined slurry mixture.

The following examples are provided to illustrate the invention in accordance with the principles of this invention but are not to be considered as limiting the invention in any way except as indicated by the appended claims.

In the Examples which follow that are directed to unsaturated hydrocarbon oxidation employing the instant cerium or thorium promoted VO(PO₃)₂ catalyst, the reactions were run in a 5/8 inch inside diameter stainless steel U-tube reactor which was immersed in a fluidized sand bath for maintaining the temperature of reaction. The lower half of the U-tube reactor was filled with catalyst having an 8-16 mesh (Standard Sieve). The cerium or thorium promoted VO(PO₃)₂ (precursor) catalyst was activated or conditioned in a stream of air with 1 volume percent of unsaturated hydrocarbon at a desired temperature for several hours at an appropriate apparent contact time over the catalyst. Following activation the temperature was decreased to the desired oxidation reaction temperature and the flow of hydrocarbon-air mixture, with or without the addition of steam, adjusted to the desired apparent contact time of between 0.5 to 3.0 seconds. The gaseous effluent oxidation reaction products from the reactor were passed through a series of water traps to adsorb the maleic anhydride and other by-products such as small amounts of acetic acid acrylic acids; the maleic anhydride being converted to maleic acid in the aqueous solution. The gaseous effluent from the U-tube reactor was analyzed by InfraRed (I.R.) and gas chromatography to determine the concentration of carbon dioxide, carbon monoxide and any unconverted hydrocarbon. The aqueous solution containing the maleic acid was analyzed by gas chromatography to determine maleic anhydride yield and selectivity. Percent conversion of hydrocarbon and percent selectivity to maleic anhydride are calculated in mole percent.

EXAMPLE 1

A cerium promoted vanadium(IV)bis(metaphosphate) catalyst was prepared as follows: 64.24 grams (0.394 moles) of vanadyl sulfate (VOSO₄) along with 4.24 grams (0.013 moles) of cerous nitrate (Ce(NO₃)₃) was added to 175 ml of acetic anhydride at ambient temperature of 25° C. with stirring. 58.76 grams (0.413 moles) of phosphorus pentoxide (P₂ O₅) was slowly added to the solution with stirring forming a slurry and allowing the liberation of exothermic heat. Excess liquid was decanted from the slurry mixture and the resulting vanadyl sulfate-cerous nitrate-phosphorus pentoxide product transferred to a furnace. The temperature of the furnace was increased at a rate of 1° C. per minute up to a maximum of 450° C. and maintained at that temperature for a period of 16 hours liberating the reaction gases. After cooling, the crystalline product was washed with water to remove any soluble residue. After drying at 120° C. the product was calcined in air at 500° C. for four hours to give a cerium promoted VO(PO₃)₂ catalyst (precursor) having an intrinsic surface area of approximately 3.1 m² /g. After calcination the catalyst (precursor) was broken up (8-16 Standard Sieve mesh size) for use in the oxidation of unsaturated hydrocarbons such as 1,3-butadiene.

EXAMPLE 2

The procedure of Example 1 was repeated using 250 ml of acetic anhydride at 25° C. Excess liquid was decanted from the slurry which was heated in a furnace at a rate of 1° C. per minute to a maximum of 450° C. and maintained at that temperature for 15 hours liberating the reaction gases. The thermally reacted catalyst was water washed to remove soluble residue. After drying at 120° C. the product was calcined in air at a temperature of 525° C. for two hours to give a cerium promoted VO(PO₃)₂ catalyst (precursor) with an intrinsic surface area of approximately 4.2 m² /g.

EXAMPLE 3

The procedure of Example 1 was repeated employing 64.24 grams (0.394 moles) of vanadyl sulfate, 1.41 grams (0.004 moles) of cerous nitrate and 250 ml of acetic anhydride to which was added 58.18 grams (0.409 moles of phosphorus pentoxide at 26° C. Excess liquid was decanted and the slurry heated in a furnace at a rate of 1° C. per minute to a maximum of 450° C. and maintained at that temperature for a period of 12 hours liberating the reaction gases. After washing with water to remove soluble residue, drying at 120° C. and calcining in air at 500° C. for four hours a cerium promoted VO(PO₃)₂ catalyst (precursor) having an intrinsic surface area of 4.8 m² /g. resulted.

EXAMPLE 4

An SiO₂ -Al₂ O₃ supported cerium promoted VO(PO₃)₂ catalyst was prepared as follows: 64.24 grams (0.394 moles) of vanadyl sulfate, 4.24 grams (0.013 moles) of cerous nitrate along with 90.0 grams of SiO₂ -Al₂ O₃ was added to 250 ml of acetic anhydride with stirring. 58.76 Grams (0.413 moles) of phosphorus pentoxide was slowly added to the solution with stirring forming a slurry and allowing the liberation of exothermic heat. Excess liquid was decanted from the slurry and the resulting mixture heated in a furnace at a rate of 1° C. per minute to a maximum of 450° C. and maintained for a period of 16 hours liberating the reaction gases. After cooling the reaction product was water washed to remove soluble residue and dried at 120° C. The dried product was calcined in air at 500° C. for 3 hours giving an SiO₂ -Al₂ O₃ supported crystalline cerium promoted vanadium(IV)bis(metaphosphate) catalyst (precursor) with an intrinsic surface area of 18.6 m² /g.

EXAMPLE 5

A thorium promoted vanadium(IV)bis(metaphosphate) catalyst was prepared as follows: 75.2 grams of vanadyl sulfate along with 12.15 grams (0.046 moles) of thorium dioxide (ThO₂) was added to 175 ml of acetic anhydride at ambient temperature (26° C.) with stirring. 78.5 grams (0.553 moles) of phosphorus pentoxide was slowly added to the solution with stirring forming a slurry and allowing the liberation of exothermic heat. Excess liquid was decanted from the slurry mixture and the resulting vanadyl sulfate-thorium dioxide-phosphorus pentoxide product transferred to a furnace. The temperature of the furnace was increased at a rate of 1° C. per minute up to a maximum of 450° C. and maintained at that temperature for a period of 16 hours liberating the reaction gases. After cooling, the crystalline product was washed with water to remove soluble residue. After drying at 120° C. the product was calcined in air at 500° C. for four hours to give a thorium promoted VO(PO₃)₂ catalyst (precursor) having an intrinsic surface area of approximately 3.8 m² /g. After calcination the catalyst (precursor) was broken up (8-16 Standard Sieve mesh size).

EXAMPLE 6

The procedure of Example 5 was repeated except that 250 ml of acetic anhydride was employed to prepare the slurry. After water washing, drying and calcination in air at 525° C. for four hours a thorium promoted VO(PO₃)₂ catalyst (precursor) having an intrinsic surface area of 7.2 m² /g. resulted.

EXAMPLE 7

The procedure of Example 5 was repeated employing 75.2 grams (0.461 moles) of vanadyl sulfate), 1.35 grams (0.005 moles) of thorium dioxide, 250 ml of acetic anhydride to which was added 67.5 grams (0.475 moles) of phosphorus pentoxide at 26° C. Excess liquid was decanted and the slurry heated in a furnace as in Example 5 for 14 hours liberating gases. After cooling, water washing, drying and calcination in air at 500° C. for four hours a thorium promoted VO(PO₃)₂ catalyst (precursor) having an intrinsic surface area of 7.5 m² /g. resulted.

EXAMPLE 8

An SiO₂ -Al₂ O₃ supported thorium promoted VO(PO₃)₂ catalyst was prepared by forming a slurry of 75.2 grams vanadyl sulfate, 12.15 grams of thorium dioxide, 90.0 grams of SiO₂ -Al₂ O₃, 250 ml of acetic anhydride and 78.5 grams of phosphorus pentoxide with stirring and the liberation of heat. The slurry was introduced into a furnace and heated at a rate of 1° C. per minute to a maximum of 475° C. and maintained at that temperature for 12 hours liberating the reaction gases. After cooling the reaction product was water washed to remove soluble residue and dried at 120° C. The dried product was calcined in air at 500° C. for 3 hours giving an SiO₂ -Al₂ O₃ supported crystalline thorium promoted vanadium(IV)bis(metaphosphate) catalyst (precursor) with an intrinsic surface area of 21.5 m² /g.

EXAMPLE 9

A cerium promoted vanadium(IV)bis(metaphosphate) catalyst was prepared as follows: 64.24 grams of vanadyl sulfate along with 2.24 grams (0.013 moles) of ceric oxide (CeO₂) was added to 175 ml of acetic anhydride at ambient temperature (26° C.) with stirring. 58.76 Grams of phosphorus pentoxide was slowly added to the solution with stirring forming a slurry and allowing the liberation of heat. Excess liquid was decanted from the slurry mixture and the resulting vanadyl sulfate-ceric oxide-phosphorus pentoxide product transferred to a furnace. The temperature of the furnace was increased at a rate of 1° C. per minute to a maximum of 450° C. and maintained for a period of 16 hours liberating the reaction gases. After cooling the crystalline product was water washed to remove any soluble residue. After drying at 120° C. the product was calcined in air at 500° C. for two hours to give a cerium promoted VO(PO₃)₂ catalyst (precursor) having an intrinsic surface area of approximately 3.8 m² /g. After calcination the catalyst was broken up into an 8-16 Standard Sieve mesh size for use in the oxidation of hydrocarbons.

EXAMPLE 10

The procedure of Example 9 was repeated except that 250 ml of acetic anhydride was employed to prepare the vanadyl sulfate-ceric oxide-phosphorus pentoxide slurry. After furnace preparation, cooling, water washing, drying and calcination as in Example 9 a cerium promoted VO(PO₃)₂ catalyst (precursor) having an intrinsic surface area of 4.4 m² /g. resulted.

EXAMPLE 11

The procedure of Example 9 was repeated employing 64.24 grams of vanadyl sulfate, 0.69 grams of ceric oxide, 250 ml of acetic anhydride to which was added 58.18 grams of phosphorus pentoxide at 25° C. Excess liquid was decanted and the slurry heated in a furnace as in Example 9 for 16 hours liberating the reaction gases. After cooling, water washing, drying and calcination as in Example 9 a cerium promoted VO(PO₃)₂ catalyst (precursor) having an intrinsic surface area 4.7 m² /g. resulted.

EXAMPLE 12

A number of runs were made employing 30 ml. of the respective cerium and thorium promoted vanadium(IV)bis(metaphosphate) catalysts of Examples 3 and 7 to oxidize 1-butene and 1,3-butadiene. The individual catalysts were loaded into the lower half of a U-tube reactor which was immersed in a fluidized sand bath. The cerium and thorium promoted catalysts (precursors) were activated in a stream of air, steam and 1 volume percent of the respective hydrocarbon at 490° C. for a period of 14 hours at an apparent contact time of approximately 3.0 seconds. Following activation of the catalyst the reaction temperature was decreased to the desired temperature and the apparent contact time adjusted to desired conditions. Results giving conversions and selectivities to maleic anhydride for the respective catalysts are shown in Table 1.

                                      TABLE 1                                      __________________________________________________________________________                                         Mole %.sup.(2)                                                                 Selectivity to                             Run                                                                               Catalyst    Contact                                                                              Temp.                                                                              Mole %                                                                              Mole %.sup.(1)                                                                       Maleic                                     No.                                                                               Promoter                                                                            Hydrocarbon                                                                           Time (sec.)                                                                          (°C.)                                                                       Steam                                                                               Conversion                                                                           Anhydride                                  __________________________________________________________________________     1  cerium                                                                              1-butene                                                                              1.00  375 24.5 97    65.8                                       2  cerium                                                                              1,3-butadiene                                                                         1.25  350 30.0 99    63.2                                       3  thorium                                                                             1-butene                                                                              0.80  450 20.5 97    63.5                                       4  thorium                                                                             1,3-butadiene                                                                         1.15  400 23.5 98    64.0                                       __________________________________________________________________________      .sup.(1) % conversion determined by gas chromatography analyses of C.sub.      in effluent gas.                                                               .sup.(2) % selectivity to maleic anhydride determined by gas                   chromatography.                                                          

EXAMPLE 13

The procedure of Example 13 was repeated employing the SiO₂ -Al₂ O₃ supported cerium and thorium promoted catalysts of Examples 4 and 8 to oxidize 1-butene and 1,3-butadiene. The respective catalyst precursor was activated in a stream of air, steam and 1 volume percent of the respective hydrocarbon at 500° C. for 14 hours at an apparent contact time of 3.0 seconds. Following activation (conditioning) of the respective catalyst the reaction temperature was decreased to the desired temperature and the apparent contact time adjusted to the desired conditions. Results are shown in Table 2.

                                      TABLE 2                                      __________________________________________________________________________                                         Mole %.sup.(2)                                Supported                  Mole.sup.(1)                                                                         Selectivity                                Run                                                                               Catalyst    Contact                                                                              Temp.                                                                              Mole %                                                                              % Con-                                                                               to Maleic                                  No.                                                                               Promoter                                                                            Hydrocarbon                                                                           Time (sec.)                                                                          (°C.)                                                                       Steam                                                                               version                                                                              Anhydride                                  __________________________________________________________________________     1  cerium                                                                              1-butene                                                                              1.05  350 20.0 96    63.1                                       2  cerium                                                                              1,3-butadiene                                                                         1.00  310 21.0 98    64.2                                       3  thorium                                                                             1-butene                                                                              1.10  400 22.4 97    64.6                                       4  thorium                                                                             1,3-butadiene                                                                         1.00  350 23.6 98    66.3                                       __________________________________________________________________________      .sup.(1) % conversion determined by gas chromatography analyses of C.sub.      in effluent gas.                                                               .sup.(2) % selectivity to maleic anhydride determined by gas                   chromatography.                                                           

We claim:
 1. A method for the preparation of a cerium or thorium promoted single phase crystalline vanadium(IV)bis(metaphosphate) hydrocarbon oxidation catalyst which comprises the steps of:forming a slurry of vanadyl sulfate, a compound selected from ceric oxide, cerous nitrate or thorium dioxide, acetic anhydride and phosphorus pentoxide with the liberation of heat; introducing said slurry into a heating zone and maintaining said zone at a temperature of at least about 325° C. for a period sufficient for the liberation of gases and forming a cerium or thorium-vanadium-phosphorus reaction product; cooling the reaction product and washing with water to essentially remove any soluble residue; drying the water washed product and calcining in air to obtain a cerium or thorium containing single phase crystalline vanadium(IV)bis(metaphosphate) catalyst.
 2. A method according to claim 1 wherein the molar ratio of cerium or thorium to vanadium, employed in the form of ceric oxide, cerous nitrate or thorium dioxide and vanadyl sulfate, is in the range of from about 1:10 to 1:150.
 3. A method according to claim 2 wherein the ratio is 1:90.
 4. A method according to claim 1 wherein the slurry is formed at ambient temperature.
 5. A method according to claim 1 wherein at least stoichiometric quantities of vanadyl sulfate and phosphorus pentoxide are employed to form the slurry with the acetic anhydride and phosphorus pentoxide.
 6. A method according to claim 1 wherein the amount of acetic anhydride employed is in the range of from about 1 to 4 moles per mole of the combined vanadyl sulfate, the ceric oxide, cerous nitrate or thorium dioxide and phosphorus pentoxide employed.
 7. A method according to claim 1 wherein the amount of acetic anhydride employed is from about 2 to 3 moles.
 8. A method according to claim 1 wherein excess liquid is decanted from the slurry prior to introduction into the heating zone.
 9. A method according to claim 1 wherein the slurry is reacted at a temperature of between about 400° C. and 460° C.
 10. A method according to claim 1 wherein the cerium or thorium-vanadium-phosphorus reaction product is dried at a temperature of about 120° C. and calcined in air at a temperature of at least 450° C.
 11. A method according to claim 1 wherein the cerium or thorium promoted single phase crystalline vanadium(IV)bis(metaphosphate) catalyst is prepared in the presence of a suitable carrier or support.
 12. A method according to claim 11 wherein the carrier or support material is added when forming the ceric oxide, cerous nitrate or thorium dioxide, vanadyl sulfate, acetic anhydride, phosphorus pentoxide slurry.
 13. A method according to claim 12 wherein the carrier or support is an aluminosilicate. 